670 Gasoline Engine Owner s Manual

Transcription

1 670 Gasoline Engine Owner s Manual

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3 PREFACE Thank you for choosing general gasoline engine of our company. The manual gives information with respect to operation and maintenance of 670 general gasoline engine, and be sure to read it carefully first before operation. Only operate as the manual tells, can insure user s safety and get the best results of the engine operation. If a problem should arise or if you have any questions about your gasoline engine, consult an authorized our company servicing dealer. Vertical shaft gasoline engine series in this manual is mainly used in the UTV, generator and high pressure washer. All information and diagrams of this manual are in accordance with the newest products at the publishing time. If revision and other change of the information descried in this manual are a little different from the actual status, our company will explain it. Our company reserves the right to make change at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. This manual should be considered a permanent part of the engine and should remain with the engine if resold. 1

4 SAFETY MESSAGES Your safety and the safety of others are very important. We have provided important safety messages in this manual and on the gasoline engine. Please read these messages carefully. A safety message alerts you to potential hazards that could hurt you or others. Each safety message is preceded by a safety alert symbol and one of three words: DANGER, WARNING, or CAUTION. These mean: You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions. You CAN be HURT if you don t follow instructions. Your engine or other property could be damaged if you don t follow instructions. 2

5 CONTENTS CONTENTS I. SAFETY PRECAUTIONS 4 II. PARTS DESCRIPTION 6 1)FEATURE 6 2)MODEL & SERIES NO 7 I II. PRE-OPERATE INSPECTION 8 1) ENGINE OIL 8 2) AIR CLEANER 11 3) Battery connection 12 IV. STARTING THE ENGINE 13 V. RUNNING THE ENGINE 14 VI. STOPPING THE ENGINE 15 VII. EXHAUST CONTROL SYSTEM SERVICE 16 1)MAINTENANCE 16 2)Replacing Parts 16 3)Tampering and Altering 16 4)Problems Affecting Exhaust Emissions 17 VIII. MAINTENANCE 18 1)MAINTENANCE SCHEDULE 18 2)MAINTENANCE METHOD 19 IX. TRANSPORT AND STORAGE 22 X. TROUBLESHOOTING 23 XI. SPECIFICATIONS 27 XII. ELECTRIC DIAGRAM 28 XIII. EASY WORN PARTS AND ACCESSORIES LIST 29 3

6 SAFETY PRECAUTIONS I. SAFETY PRECAUTIONS Indicate a possibility of invalid warranty and personal or equipment damage if instructions are not followed. Please pay special attention to the followings: 1. Strictly set the engine according to the regulated power on the owner's manual. Do not overload, overspeed the engine or run it with low load and at low speed in a long time. 2. Use specified grade of gasoline. The fuel should be fully deposited and filtrated before use. Keep clean the fuel filler, change the oil periodically. 3. Periodically check the installation, connection and the degree of tightness of the fixed bolt. Tighten it if necessary. 4. Periodically clean the element of the air cleaner, change it when necessary. 5. The engine is air-cooled, so clean the radiator, fan cover and fan in time in order to make the engine cool normally. 6. The operator should be familiar with the working principle and structure of the gasoline engine, knowing how to make an emergent stop and the operation of all controlling parts. Any one without training is forbidden to operate the engine. Keep periodical maintenance. Solve problems in time. Do not run the engine in spite of malfunction. 7. Running the engine in a well -ventilated place, keep it at least one meter away from building walls or other equipments, keep away from 4

7 SAFETY PRECAUTIONS inflammables such as gasoline, matches and so on to avoid possibility of fire. 8. Refuel in a well-ventilated area with the engine stopped, and in places refueling or storing gasoline, no smoking and any flames or sparks. 9. Refuel the fuel tank not too full so as to avoid fuel s spilling out. If there is spilled fuel around, be sure to clean it thoroughly before starting. 10. Do not run the engine in airtight or ill-ventilated places. 11. The exhaust muffler is very hot during running the engine even after the engine stops. Never touch it, or you may get burns. Transport or store the engine with it cooling down entirely. 12. Safe warning label: Please carefully read warning label before operating. Our company will not assume any responsibility for person hurt, or equipment damaged caused by disregarding this warning label. 5

8 PARTS DESCRIPTION II. PARTS DESCRIPTION 1. Feature Muffler Decorative board Lug Radiator Shroud assy. Shroud shield Air cleaner Lug Spark plug Oil dipstick Oil filter assy Solenoid switch Starting motor 6

9 PARTS DESCRIPTION 2. Model & series no. Model Serial no. Finished product no. 7

10 PRE-OPERATE INSPECTION III. PRE-OPERATE INSPECTION 1. Engine Oil Engine oil is a key factor in deciding the engine s performance. Do not apply engine oil with additives or 2-stroke gasoline engine oil, because they haven t enough lubrication, and may shorten the engines service life. Check the engine with it stopped on a level ground. Use 4-stroke engine oil for API service classification SE class or equivalent, and always check API service label on the oil container to be sure it includes the letters SE or equivalent. SAE Engine oil capacity: L Engine oil recommended: SAE10W-30 environment temperature Check method: 1) Remove the dipstick and clean it. 2) Reinsert the dipstick into the oil filling hole without screwing it, and check oil level. 3) If the oil level is too low, add the recommended engine oil up to the oil upper level. 8

11 PRE-OPERATE INSPECTION 4) Reinstall the dipstick. A s s e m b l i n g Oiling hole on the oiling hole Sealing ring Oil plug Oil dipstick Oil upper limit Oil lower limit Oil drain plug Flat washer Draining port Assembling on the draining oil port Engine oil change: Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. It is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. Please dispose of used engine oil in a manner that is compatible with the environment. 1)Screw the oil dipstidck out. 2)Tilt the gasoline engine and let the oil overflowing out from the hole. 9

12 PRE-OPERATE INSPECTION 2. AIR CLEANER Never run the engine without an air cleaner, or severe wear of the engine may be resulted in. Locking lever assy. Intake tube cover Decorative board Hex. Flange bolt small ser. M6 35(2pcs) Element assy. Locking nut assy. Air cleaner seat Gasket Clasper Air cleaner case Remove the fan cover decorating plate Remove the air cleaner housing. Remove foam element or paper element, paying attention to prevent dust and foreign matter entering into air cleaner. Check, clean or replace damaged air cleaner parts. Check, clean or replace damaged air cleaner parts. 10

13 PRE-OPERATE INSPECTION 3. Battery connection Battery Connect to terminal product Rectifier Use 12V and more than 18A.H battery, connect its positive lead to start relay terminal while connect its negative lead to engine mounting screw, base screw or other grounding point with the engine.(see Fig. 2) Check the battery's connecting point; make sure that it is tight and not rusted. If rusted, clean and connect. Apply the grease on the end and connector lug. 1. The battery may give off explosive gas, keep sparks, flames and cigarettes away. Charge or use it indoors with good ventilation. 2. The battery contains sulphuric acid (electrolyte). Contact with skin or eyes may cause severe burns. If electrolyte gets in your skin, flush with water; if gets in your eyes, flush with water for at least 15 minutes and call a physician at once. 3. Electrolyte is poisonous. If swallowed, drink large quantities of 11

14 PRE-OPERATE INSPECTION water or milk, and follow with milk of magnesia or vegetable oil and call a physician. 4. Keep out of reach of children. 1. Do not add tap water to the battery instead of distilled water, otherwise the battery service life will be shortened. 2. Do not add distilled water over electrolyte upper level mark, if not, electrolyte will spill out to corrupt the engine part. If so, be sure to wash them away with water. 3. Make sure not to connect the battery leads in reverse order, or short-circuit or breaker s trip may be resulted in. 12

15 Starting the engine IV. Starting the engine 1)Before starting the engine, check each pre-operation check steps above mentioned, don t start the engine until all requirements above mentioned are met with. 2)Check the choke for CLOSE position. 3)Switch on the power supply and start the engine. 13

16 RUNNING THE ENGINE V. RUNNING THE ENGINE After starting, move the choke lever toward fuel tank direction to make the choke at OPEN position The engine speeds is adjusted well in the factory, so the engine can run at specified speed after starting. Don t adjust the speeds by yourself with any purpose or it will hurt the person and damage the engine. If needing to adjust the speeds, please contact our company authorized dealer. Otherwise user have a special tool and repaired ability. 14

17 STOPPING THE ENGINE VI. STOPPING THE ENGINE After removing engine load, can directly turn the terminal-products stop switch to O position or STOP position for stopping engine. Don t stop the engine when the engine is running with maximum load at high speed to avoid the engine damaged. 15

18 EXHAUST CONTROL SYSTEM SERVICE VII. EXHAUST CONTROL SYSTEM SERVICE With the engine running, carbon monoxide, oxide of nitrogen and hydrocarbon will produce, and in certain conditions, oxide of nitrogen and hydrocarbon will react chemically each other to make smoke while carbon monoxide is toxic, so exhaust control of them is very important. The company decreases the exhaust emissions by introducing poor-fuel carburetors and other devices into the engine to solve the problem. To keep the exhaust of your engine with in the standard exhaust emission, pay attention to the followings: 1. Maintenance Maintain the engine periodically in accordance with the maintenance schedule in the manual. The maintenance schedule is made out on the base of normal use in normal conditions, if using under heavy load, dusty or wet circumstances or in high temperature, service of the engine should be done more often. 2. Replacing Parts To ensure the best quality and reliability, use only new genuine our company parts or their equivalents for repair and replacement. 3. Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit. Among those acts that constitute tampering are: 16

19 EXHAUST CONTROL SYSTEM SERVICE 1) Removal or alteration of any part of the intake, fuel, or exhaust systems. 2) Altering or defeating the governor linkage or speed-adjusting mechanism to cause the engine to operate outside its design parameters. 4. Problems Affecting Exhaust Emissions 1)Difficult starting or difficult stopping. 2)Engine speed is unstable. 3)Muffler exhausts black smoke, blue smoke or fuel and oil consume abnormal. 4)The engine backfire, abnormally stop or fire gun. 5)Too early ignition. 17

20 MAINTENANCE VIII. MAINTENANCE 1. MAINTENANCE SCHEDULE In order to keep the engine well, must periodically service and adjust the engine. Service shall be as following schedule. Item Frequency Each time First month or 20 hrs Each season or 50 hrs Every 6 month or 100 hrs Each year or 300 hrs Engine oil Oil level check Replace Air cleaner Check Clean replace Spark plug Clean, adjust Replace Oil strainer Replace Valve clearance Check-adjust * Cylinder head Clean * * This items should be serviced by company authorized dealer, unless you have the proper tools and mechanically proficient. Service more frequently when used in dusty areas. 18

21 MAINTENANCE 2.MAINTENANCE METHOD 1. Replacement of engine oil Drain the engine oil rapidly and completely out when the engine is hot. 1) Remove the oil dipstick, drain plug and washer and drain engine oil thoroughly. Reinstall the drain plug and screw in it securely. 2) Fill the recommended engine oil and check oil level with oil dipstick. 3) Reinstall the oil dipstick and tighten it securely. Please dispose of used engine oil and the oil containers in a manner that is compatible with the environment. We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation. Do not throw it in the trash or pour it on the ground or down a drain. 2. Maintenance of air cleaner A dirty or damaged air cleaner will allow dust entering into the engine, causing rapid engine wear. So, service the air cleaner in time. Remove the bolt and air cleaner cover. Be careful to prevent dirt and debris from falling into the air cleaner base opening, Remove the foam element or paper element. Check, clean or replace the damaged air cleaner parts. Reinstall the air cleaner parts, then bolt and screw down it. Never clean the air cleaner element with gasoline or low flash-point detergents, or explosion may happen. Clean the foam filter with soapy water, blow the paper element with compressed air or lightly tap off dust and never dry to brush. 19

22 MAINTENANCE 3.Maintenance of spark plug In order to ensure the engine normal running, gap of the spark plug must be correct and no deposit around the spark plug mm SPARK PLUG MODEL NGK: BP5ES/BPR5ES TORCH: F6TC/F6RTC Don t touch the muffler to avoid burn in the engine running or just stopping a moment. 1) Remove the spark plug cap. 2) Clear away dirt around the spark plug base. 3) Dismantle the spark plug with a spark plug wrench. 4) Visually check the spark plug. Clean with a steel brush. If the insulator is damaged, replace the spark plug instead. 5) Measure the spark plug clearance with a feeler. The clearance should be 0.7~0.8mm. If adjustment is necessary, bend the side electrode carefully. 6) To avoid cross-threading, first, screw in spark plug by hand, then tighten with a spark plug wrench to compress the gasket. 7) If a new spark plug is used, more twist 1/2 turns after compressing the gasket. 20

23 MAINTENANCE 8) If reinstalling the used spark plug, just more twist 1/8-1/4 turns. 1) The spark plug must be tightened securely, or it may become very hot to damage the engine. 2) Only use recommended spark plug or the equivalent. Incorrect heat range of the spark plug may damage the engine. 4. Idle speed adjustment of the carburetor Start the engine and preheat it to normal operating temperature. Adjust the throttle stopping screw to obtain minimum idle speed. Minimum idle speed: 1,600(±100)rpm 21

24 IX. TRANSPORT AND STORAGE TRANSPORT AND STORAGE Do not incline the engine so as to avoid fuel s spill in transporting. Spilled fuel or fuel vapor may ignite to cause fire. If suspension for a long time, storage should be as followings: 1.The storage area is dry and free of dust. 2.Completely drain fuel out of the fuel tank and carburetor. Fuel is extremely flammable and explosive under certain conditions. Keep smoke, fire and spark away from operating site. Turn the fuel cock to OFF (close) position and remove the oil drain plug of the carburetor. Turn the fuel cock to ON (open) position to drain the fuel of the fuel tank by carburetor to the container. Reinstall the oil drain plug. 3. Replace engine oil. 4. Remove the spark plug. Fill about a spoon of fresh engine oil onto the cylinder. Crank the engine up to distribute engine oil evenly. Reinstall the spark plug. 5. Lightly pull the recoil starter rope until the resistance is felt. Close the choke to protect the dust from entering in. 6. Cover the engine to protect dust entering. 22

25 TROUBLESHOOTING X. TROUBLESHOOTING 1. START ENGINE DIFFICULTLY TROUBLE CAUSE REMEDY Normal cylinder compression Abnormal cylinder compression. Normal spark plug spark Normal fuel supply system. Something wrong with the fuel system. Normal high High-tension line no tension line spark. spark Ignition system. Fuel supply is not smooth or no fuel supply. Fuel supply is normal. Spark plug is in bad conditions Normal spark plug There is no enough fuel in fuel tank and fuel cock is closed. Air vent in the fuel filler cap is clogged Fuel cock is clogged Improper or clogged main oil flow hole. Fill fuel, open fuel cock. Dredge air vent. Clean first and then dredge Readjust or clean, blow to get through. Needle valve is not closed Dismantle needle valve and repair, clean, blow to get properly or start hole is clogged. through. Float is damaged or sticking. Repair float Fuel is too filthy or deteriorated Replace There is water in fuel. Replace Too much fuel in engine Drain extra fuel, dry up spark plug electrodes. Wrong fuel brand Select proper fuel brand corresponding with the requirements. Too much carbon deposit and dirt around electrodes. Clear away. Electrodes are burn damaged Replace spark plug. seriously or insulators damaged. Improper electrodes gap. High tension line is damaged. Ignition coil is damaged. Magneto loses magnetism. Piston ring is worn to or even over its wear limit Piston ring is broken. Piston ring is sticking. Spark plug is not installed tighten or without a gasket. Air leakage between cylinder block and cylinder head. Air leakage in the valves Adjust to proper value. Replace Replace Replace Replace Replace Clear up carbon fouling. Tighten with a gasket in. Check cylinder gasket, and the flatness of the surface by which cylinder block contacting with cylinder head Tighten cylinder head bolts in stipulated order to stipulated torque. Check valve. Clearance and tightness, repair if necessary. If still can t starting, have the engine to our authorized dealer for repairing. 23

26 TROUBLESHOOTING When testing the spark plug, never hold the high- voltage wire of the spark plug with wet hand. Make sure there is no spilled fuel outside the engine and that the spark plug isn t dipped with fuel. To prevent fire, keep sparks far away from the spark plug mounting hole. 2. GASOLING ENGINE POWER OUTPUT INSUFFICIENCY: TROUBLE CAUSE REMEDY When increasing throttle, speed increase slow or even decrease and stop running Fuel supply system Poor compression Air in fuel line or fuel line clogged Main oil flow hole is not adjusted properly In carburetor, needle valve hole and main oil flow hole clogged. Fuel cock is clogged up. Too much carbon deposit in combusting chamber. Too much car bon fouling in muffler and exhaust pipe. Air cleaner is clogged up. Intake pipe is leaking Piston or cylinder or piston ring is worn Air leakage from the surface by which cylinder block contacting with cylinder head. Too big or too small valve clearance. Valve tightness is poor. Exhaust air or dredge fuel line Readjust Clean and blow to get through Clean, replace damaged part Clear away Clear away Clean air cleaner filter element Repair or replace Replace the worn Replace cylinder gasket Readjust Repair 3. GASOLINE ENGINE CANNOT RUNNING SMOOTHLY TROUBLE CAUSE REMEDY Knocking sound Abnormal combustion Spark lacking 24 Piston, cylinder or piston ring is worn excessively. Replace the worn Piston pin and piston pin hole are worn excessively. Replace piston or piston pin Tie rod small head is worn excessively. Replace tie rod Roller bearing for crankshaft main shaft is worn. Replace roller bearing Engine is too hot Shoot trouble Too much carbon deposit in combustion chamber Clear away Improper gasoline brand or low gasoline quality Replace with qualified gasoline There is water in float chamber Clean improper spark plug electrodes clearance Adjust Incorrect ignition time Readjust Something wrong with induced coil, and so on Check and replace damaged parts

27 TROUBLESHOOTING 4. STOP SUDDENLY WHEN RUNNING TROUBLE CAUSE REMEDY Fuel is finished Refill fuel Fuel supply system Carburetor is clogged Float is leaking Check fuel line and dredge Repair Stop suddenly when running. Ignition system The other Needle valve is sticked Spark plug is punctured, or shortcircuited by carbon deposit Side electrode of spark plug is dropped out High-tension wire is dropped out Ignition coil is punctured or shortcircuited Parking wire is located on engine body Cylinder is seriously scored and valve dropped out Dismantle float chamber and eliminate it Replace spark plug Replace spark plug Weld on Replace ignition coil Find out meeting and insulate Repair or replace damaged parts 5. GASOLINE ENGINE IS OVERHEAT TROUBLE CAUSE REMEDY Oil insufficient or wrong oil ratio in the gasoline Refill engine oil Exhaust pipe blocked up Shroud leaking Clean exhaust pipe Repair damaged part Gasoline engine is overheat Cooling fins blocked by foreign matter Clear cooling fins Cooling fan i loosen and misfunction Reinstall well Connection rod deformation to make piston and Replace connection rod cylinder bushing side wear Cylinder or piston or piston ring is worn to make Replace the worn parts hunting between cylinder and crankcase Improper adjustment of engine governor to produce Readjust engine governor speed high. Crankshaft main bearing burnt out Replace main bearing The gasoline engine should be kept about 80 ~ 110 temperature around the outlet of the shroud. If the temperature is too high, it will indicate the gasoline engine overheating. 25

28 TROUBLESHOOTING 6. THERE EXISTS ABNORMAL NOISE WHEN ENGINE RUNNING TROUBLE CAUSE REMEDY Beating sound Piston, piston ring or cylinder is worn Connection rod or piston pin and piston pin hole are worn Crankshaft main neck is worn Replace the worn part Replace the worn part Replace bearing Piston ring is broken Carbon deposition too much Metal beating sound when Improper fuel brand abnormal combustion occurs Engine is overheat Replace piston ring Remove the carbon deposition Replace fuel Find a cause and eliminate it The other Improper valve clearance Fly wheel is not connected with crankshaft tightly Readjust valve clearance properly Connect tightly 26

29 SPECIFICATIONS XI. SPECIFICATIONS 1. MAIN SPECIFICATON Model R670 L W H(not including crankshaft output terminal) Dry Weight 48 Engine Type twin cylinder horizontal,4-stroke, (OHV) Displacement 670 Bore Stroke Theoretical Maximum Power 15.5kw/3600r/min Recommended Using Power 15kw/3600r/min Maximum Torque 45N m/2500r/min Fuel Consumption 374g/kw h Cooling System Forced air Ignition System Transistor magneto ignition(tci) PTO Shaft Rotation Horizontal shaft output DATA ADJUSTMENT: Items Technical data Service Spark plug clearance 0.7~0.8mm To see P20 Valve clearance (cold engine) Igniter clearance intake:0.15±0.02mm exhaust:0.20±0.02mm 0.4~0.6mm to see our company authorized dealer Specification is subject to change without notice. For further information, please contact our company dealer. 2. TORQUE OF IMPORTANT BOLTS: Items Thread dia. Torque value N m Kg m Connecting bar bolt M Cylinder head bolt M Flywheel nut M Crankcase cover bolt M Gap adjusting nut M Rocker bolt M

30 ELECTRIC DIAGRAM XII. ELECTRIC DIAGRAM 28

31 EASY WORN PARTS AND ACCESSORIES LIST XIII. EASY WORN PARTS AND ACCESSORIES LIST EASY WORN PARTS LIST: ACCESSORIES LIST: CYLINDER HEAD CAP GASKET CYLINDER HEAD GASKET SPARK PLUG OIL SEAL BREATH GROOVE GASKET CRANKCASE GASKET CARBURETOR GASKET C A R B U R E T O R H E A T INSULATION WASHER INTAKE PORT GASKET AIR CLEANER GASKET EXHAUST PORT GASKET SLEEVE FORCING BAR 29

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